Method for compacting particulate material by compression

ABSTRACT

The invention relates to a method for compacting particulate material by compression. The invention especially relates to a method for compacting particulate material, including a compression compacting method for preparing units of particulate materials. Said particulate materials to be treated can comprise, but are not limited to, cement, calcium, gypsum, mortar, combinations thereof and the like, in order to improve the packaging, storage, transport, presentation, dosage and preparation thereof, thereby benefiting the manufacturer, the distributor and the consumer. The invention reveals the possibility of applying different pressures for the compression and shaping of the compacted product into different geometrical shapes, for the packaging, storage, transport, presentation, dosage, preparation and use thereof, from the opening of the packaging to the final application.

TECHNICAL FIELD

The present invention aims to a method for compacting particulate material by compression.

Specifically, the invention relates to a method for compacting particulate material that includes a compacting by compression method for compression for the preparation of particulate materials units.

PRIOR ART

There are some developments such as that filed in the Britain application No. 2007/0006725 owned by THOMAS HALL and COLIN RAYMOND published in 2007, which discloses a water soluble packaging which allows for the whole packaging and cement to be fed in the mixers. Once the water is added, the packaging is dissolved. This development significantly reduces the losses of cement and the untidiness occurred during the preparation of the mixture, as well as the personal contact with the cement.

Thus, there are continuous needs for simply and economically improving the methods for transportation and handling of the powdered cement or other particulate materials.

DISCLOSURE OF THE INVENTION Technical Problem

There are different materials and/or products of different industries and technologies whose final use is given as a powder.

For example, in the cement industry, white cement, grey cement or mortar is commonly used in concrete-based buildings and is used for preparing cement grout with the combination of different aggregates and water, so once it has set, it is useful for the creation of masses of columns, beams, walls, etc., along with other construction elements such as metal rods, additives, etc.

Cement is one of the most important and necessary materials with a wide range of applications in construction. The cement powder is usually transported by pneumatic conveyors due to its fine dust nature. The cement powder is aimed to be packaged in bags and sent to its sale destination and subsequent purchase and use. Throughout this process, before the final aggregates for the formation of concrete, the cement undergoes continuous losses due to its highly volatile powder condition. This is due to the fact that the cement powder comprises a particle size in the range of 15 pm to 40 pm of cohesive nature. As a result thereof, the cement particles tend to rise and merge with the surrounding air, so there are substantial losses throughout the process, besides the problems of the respiratory system of the persons who are in direct contact with the process.

Another drawback is that, usually, the packaging and final presentation of this type of materials or products are limited to irregular shapes due to the same nature of its powdered state, which sometimes bears disadvantages such as requiring a second packaging for easing the stacking, transportation, labeling, automation and corporate image communication, among others.

Solution to the Problem

A first object of the present invention is to create a method for compacting particulate material by compression for its packaging, storage, transportation, presentation, filling, preparation and use from the opening of its packaging until its final application.

Another object is to retain the properties of the particulate material during the compaction.

An additional object is to treat the particulate material without the consequent suspension in the air thereof, thus avoiding the respiratory, dermatological and pollutant issues that the handling of the material by the surrounding personnel may comprise.

A further object of the present invention is to facilitate the preparation of the mixture of the material with water, as the end user is not required to measure the material volume, but to apply a certain amount of water.

Finally, another object is to show the corporate image embedded in the same material.

According to previous objects, the present invention lies in a compacting by compression method for packaging, storage, transportation, presentation, filling, preparation and use of the particulate material.

The novel features that are considered as the base of the invention are cited in the enclosed claims and the additional advantages thereof will be better understood by the following detailed description with its preferred embodiments.

Advantageous Effects of the Invention

The convenience of the particulate material treated by the present invention lies in the fact that it does not need any additives for its compaction and decompaction, so once it is arranged for its use, same is sectioned by portions thus allowing an easy mechanical decompaction, according to the need, and any means may be added for conforming the required mixture and in order for it to be commonly treated.

Likewise, the mechanical properties of the compacted material after setting do not differ beyond 5 MPa when compared with the non-compacted material. This is disclosed in the laboratory results according to the NTC 220 standard, wherein 3 samples underwent testing: a first compacted sample at a 3 MPa pressure; a second compacted sample at a 3 MPa pressure but with a 2 weeks ageing; and a third non-compacted sample.

The tests of the three cited samples had the same temperature (23° C.), relative humidity of the environment (76%), water temperature (23° C.), cement amount (900 gr), sand weight (2475 gr), water volume (460 cm³), diameter of the largest base of the cylinder (100.9 mm) and water cement ratio (0.51) features.

The average results of compressive strength were after 28 days of setting, 27.7 MPa for the first sample, 25.4 MPa for the second sample and 29.5 MPa for the third sample.

On the other hand, the thermogravimetry (TG) laboratory tests, which objective is to find the humidity percentage in the samples at a 105° C. temperature, show that the cement compaction in fact reduces the water absorption capacity, having an average of 0.81% humidity with a 0.053% deviation, as compared to 0.87% humidity of the non-compacted samples.

Finally, the X-ray diffraction (XRD) laboratory tests that aim to show the chemical composition of the samples support the lack of hydrated phases and the 1.2% calcium hydroxide percentage in the first analyzed sample and 1.3% in the second analyzed sample, which is similar to the 1.8% of the third sample performed with non-compacted cement.

The compact presentation of the material treated under the method of the present invention is a step before the final packaging that is normally done in the industry. For the process of the present invention, it is possible to use different shaped molds, with special cavities, such as reglets to determine volumes and with different shapes defined according to the specific need. According to the present invention, there is the possibility of applying different pressures for compression and conformation into different shapes such as cylinders, cubes and other geometric shapes; to be later packed for packaging, storage, transportation, presentation, filling, preparation and use of the compacted product starting from the opening of its packaging until its final application. Once the particulate material is compacted to a certain pressure, same assumes the shape of the cavity and the structural stability, thus facilitating the handling for the end user at the filling and cleaning levels. Also, the use of additives for undoing the compaction will not be needed later.

With the method of the present invention, the end user is not the only one benefited, the manufacturer is also benefited, who guarantees a product without the need to be modified by intermediaries outside the production, both in quantity and in content and presentation.

Finally, the intermediaries are also benefited as they do not have to devote time for training, they have a cleaner local, and they are able to better use the space.

The compressed material units can be packaged in regular and irregular shapes defining the origin of the product, with the consequential benefits related an increased advertising impact that may be associated with the resulting product.

BRIEF DESCRIPTION OF THE DRAWINGS Best way of Carrying out the Invention Method of Carrying out the Invention

The present invention aims to a compacting by compression method for packaging, storage, transportation, presentation, filling, preparation and use of the particulate material.

Particularly, the invention relates to a method for compacting particulate material that includes a compacting by compression method for compression for the preparation of particulate materials units.

These particulate materials to be treated, which may include but not be limited to cement, mortar, plaster, calcium, combinations thereof or the like, for improving its packaging, storage, transportation, presentation, filling, preparation and use, being thus the manufacturer, distributor and consumer benefited. The particle size of these materials is in the range of 10 to 50 pm and is cohesive in nature.

The method of the present invention comprises:

1. a first step of selection of the particle size of the particulate material, by a first sieving;

2. a second step of placing the particulate material in a compression device, wherein an additional content of this particulate material is added, equivalent to the interstitial air with respect to the total capacity of the material in the compression device;

3. a third step wherein said compression device is centered on the compression machine;

4. a fourth compression step, wherein the material is compressed and compacted at a pressure between 2.3 and 3.8 MPa, preferably, 3 MPa;

5. a fifth separation step of the compressed material of the compression device; and

6. a sixth step wherein, once the compressed material is removed, it is conformed to the unit of particulate material ready for packaging in a compression state .

The final product comprises a unit of compressed material manufactured according to the method of the present invention, with several attractive features such as a suitable vibration tolerance, better mechanical strength, greater humidity resistance, better preservation, etc.

Studies of vibration in a frequency range between 20 Hz and 10 kHz subjecting the compacted product to a vertical vibration with a 500 m/s2 acceleration were performed. Said frequency is used in tests of transportation of products such as fruit to avoid its deterioration, according to the document ‘Effect of Truck Vibration during Transport on Damage to Fresh Produce Shipments in Thailand’ published in the Journal of Applied Packaging Research, volume 3, no. 1, January, 2009. The data were obtained through a signal conditioner at a 200,000 samples per second sampling frequency. The vibration frequency control was obtained by means of the control of a three-phase alternating current motor with a power of 745 W by means of a frequency inverter.

The convenience of the particulate material treated by the present invention lies in the fact that it does not need any additives for its compaction and decompaction, so once it is arranged for its use, same is sectioned by portions thus allowing an easy mechanical decompaction, according to the need, and any means may be added for conforming the required mixture and in order for it to be commonly treated.

Likewise, the mechanical properties of the compacted material after setting do not differ beyond 5 MPa when compared with the non-compacted material. This is disclosed in the laboratory results according to the NTC 220 standard, wherein 3 samples underwent testing: a first compacted sample at a 3 MPa pressure; a second compacted sample at a 3 MPa pressure but with a 2 weeks ageing; and a third non-compacted sample.

The tests of the three cited samples had the same temperature (23° C.), relative humidity of the environment (76%), water temperature (23° C.), cement amount (900 gr), sand weight (2475 gr), water volume (460 cm³), diameter of the largest base of the cylinder (100.9 mm) and water cement ratio (0.51) features.

The average results of compressive strength were after 28 days of setting, 27.7 MPa for the first sample, 25.4 MPa for the second sample and 29.5 MPa for the third sample.

On the other hand, the thermogravimetry (TG) laboratory tests, which objective is to find the humidity percentage in the samples at a 105° C. temperature, show that the cement compaction in fact reduces the water absorption capacity, having an average of 0.81% humidity with a 0.053% deviation, as compared to 0.87% humidity of the non-compacted samples.

Finally, the X-ray diffraction (XRD) laboratory tests that aim to show the chemical composition of the samples support the lack of hydrated phases and the 1.2% calcium hydroxide percentage in the first analyzed sample and 1.3% in the second analyzed sample, which is similar to the 1.8% of the third sample performed with non-compacted cement.

The compact presentation of the material treated under the method of the present invention is a step before the final packaging that is normally done in the industry. For the process of the present invention, it is possible to use different shaped molds, with special cavities, such as reglets to determine volumes and with different shapes defined according to the specific need. According to the present invention, there is the possibility of applying different pressures for compression and conformation into different shapes such as cylinders, cubes and other geometric shapes; to be later packed for packaging, storage, transportation, presentation, filling, preparation and use of the compacted product starting from the opening of its packaging until its final application. Once the particulate material is compacted to a certain pressure, same assumes the shape of the cavity and the structural stability, thus facilitating the handling for the end user at the filling and cleaning levels. Also, the use of additives for undoing the compaction will not be needed later.

With the method of the present invention, the end user is not the only one benefited, the manufacturer is also benefited, who guarantees a product without the need to be modified by intermediaries outside the production, both in quantity and in content and presentation.

Finally, the intermediaries are also benefited as they do not have to devote time for training, they have a cleaner local, and they are able to better use the space.

The compressed material units can be packaged in regular and irregular shapes defining the origin of the product, with the consequential benefits related an increased advertising impact that may be associated with the resulting product.

The preferred embodiments of the invention have been depicted solely by way of example. In this regard, it will be noted that the method for compacting particulate material by compression of the present invention, as well as the arrangements of each step, may be chosen from a plurality of alternatives without departing from the spirit of the invention according to the following claims.

Industrial Applicability

With the method of the present invention, the end user is not the only one benefited, the manufacturer is also benefited, who guarantees a product without the need to be modified by intermediaries outside the production, both in quantity and in content and presentation.

Finally, the intermediaries are also benefited as they do not have to devote time for training, they have a cleaner local, and they are able to better use the space.

The compressed material units can be packaged in regular and irregular shapes defining the origin of the product, with the consequential benefits related an increased advertising impact that may be associated with the resulting product. 

1. A method for compacting particulate material by compression, comprising: (i) a first step of selection of the particle size of the particulate material, by a first sieving; (ii) a second step of placing the particulate material in a compression device, wherein an additional content of this particulate material is added, equivalent to the interstitial air with respect to the total capacity of the material in the compression device; (iii) a third step wherein said compression device is centered on the compression machine; (iv) a fourth compression step, wherein the material is compressed and compacted at a pressure between 2.3 and 3.8 MPa, preferably, 3 MPa; (v) a fifth separation step of the compressed material of the compression device; and (vi) a sixth step wherein, once the compressed material is removed, it is conformed to the unit of particulate material ready for packaging in a compression state. 